Strategies to Introduce Single-Use Technology in Legacy Facilities
Lincolnton Kaizen Event Final Pitch - Infographics
1. INFOGRAPHICS FINISH GOOD ASSEMBLY
Team Picture
Team Members (Left to Right):
-Jeff Sigmon (Test Eng)
-Fernando Mejia (Repair Mgr)
-Kathy Harvey (Mfg Associate)
-Natasha Lott (Co-Lead)
-Jean Sylvester (Mfg Associate)
-Commong Herr (ME Tech)
-Derek Baker (Team Lead)
2. INFOGRAPHICS FINISH GOOD ASSEMBLY
Area Profile
Event Description:
Preliminary Objectives:
20% WIP reduction (July WIP PI $57,643) Name Function Name Function
PFEP (second hand load, final assembly and packout material) Derek Baker Team Lead Jeff Sigmon Test Eng.
Productivity improvement through standard work in new layout. Fernando Mejia Repairs Mgr Commong Herr METech
Reduce footprint 20% Taking 3 WC to 1 and a feeder line. Natasha Lott Prod Coord
Cycle Time reduction (implement new tester) Jean Sylvester Mfg Assoc
Kathy Harvey Mfg Assoc
Team Lead:Derek Baker
Co-Lead: Natasha Lott Training Required Element Members needing
Location: Lincolnton, NC ex:intro to lean ex:7 waste ALL
Facilitator: Blair Keeter
Consultant: Mark Hamel
Sponsor: Mike Vann
VSIP Linkage (reference #) #1-#6
Demand Requirements (TAKT Time):
Available Time/Customer Demand = 435min/45 units = 9.7 min
Process Information:
Scope: Infofraphics Final Assembly starting at 2HL to FG pack out
Area Owner: Zenaida Camacho Prod Coordinator: Natasha Lott
# of Workcells: 2 # of MTS SKUs: 48 (Info 33; CTL 15) # of MTO SKUs: 63 (Info 52; CTL 11)
Safety Concerns: Area is cluttered, MTO material on pallets
Current Situation and Problems:
1- Infographics demand increasing due to MAKK TOW - need to improve
line efficiency (workcell layout, material presentation). 2- Integration of
new tester to service all 3 Infographics product families (readers,
controllers & misc). 3- July WIP PI $57,643 (Info $35,246, CTL - $22,397)
KAIZEN EVENT AREA PROFILE
Event Dates:
7/7/09 - 7/10/09
Finish Goods Assembly - Infographics
3. INFOGRAPHICS FINISH GOOD ASSEMBLY
Pre-Kaizen Situation
• No standard work
• Excess MTO/MTS Inventory
• 5 individual testers
• 20% utilization of new test tower
• 25 minute test cycle times
• Poor material flow
• 5S score of 2
• Excess inventory of PCBs
4. INFOGRAPHICS FINISH GOOD
ASSEMBLYTarget Sheet
Start Target Day 1 Day 2 Day 3 Day 4 End Difference % Improvement*
WIP $57,643 $57,643 $57,643 $38,643 $38,643 $38,643 $38,643 $19,000 33%
875 700 875 875 607 607 607 Sqft 268 31%
25% 100% 25% 25% 25% 50% 75% 50% 50%
50% 100% 50% 50% 75% 90% 90% 40% 40%
50% 100% 50% 50% 75% 75% 90% 40% 40%
25 10 25 25 4 4 4 min 21 84%
20% 100% 20% 20% 100% 100% 100% 80% 80%
26666 13333 26666 FT 26666 FT 0 0 FT 0 FT 26666 100%
$22,397 $17,918 $22,397 $22,397 $15,397 $18,397 $18,397 $7,000 31%
6 3 6 6 4 4 4 2 33%
12048 6024 FT 12048 FT 12048 FT 0 0 FT 0 FT 12048 100%
$35,246 $28,197 $35,246 $35,246 $23,246 $20,246 $20,246 $12,000 34%
11388 9111 11388 FT 11388 FT 0 0 FT 0 FT 11388 100%
$35,246 $28,196.80 $35,246 $35,246 $23,246 $20,246 $20,246 $12,000 34%
5 3 5 5 3 3 3 2 40%
NO YES NO NO NO YES YES NA 100%
NO YES NO NO NO YES YES NA 100%
NO YES NO NO NO YES YES NA 100%
2 5 2 2 4 4 4 2 100%
Average Cycle Time (min)
Integration
5S score
single piece flow exists
Standard work exists
Process Attributes
leadership standard work exists
Key Measurement
Info- Controllers
Product touches
Infographics (Total)
Standard work in process
Floor space reduction (SQFT)
PFEP
Material Presentation
Test
Walk distance (power supply)/YR
Walk distance (power supply)/YR
Info-Options
MTO Inventory
WIP
Info-Misc
IMPACT
Walk distance (MTO/Inventory)/YR
Product touches
MTO Inventory
5. Before Kaizen After Kaizen
Operation Problem Actions Taken Results
INFOGRAPHICS FINISH GOOD
ASSEMBLYImprovement Ideas
Cell Layout Excess inventory: MTO/MTS
Poor material flow
84% reduction in test cycle
time. 31% reduction in floor
space.
Develop layout to include new
test tower while creating one
piece flow
6. Before Kaizen After Kaizen
Operation Problem Actions Taken Results
Control Measures
INFOGRAPHICS FINISH GOOD
ASSEMBLY
Improvement Ideas
MTS/MTO
Replenishment
Material is brought to the line
separate and placed on floor.
Excess inventory, no kanban setup.
Inventory levels
consistent, no material on
floor.
Kit carts built to support 4 hours
of work
•Taped designated
locations for carts
•Kanban established
with corresponding label
to aid with stockroom
replenishment.
•Visually controlled to
help with inventory
levels
7. Operation Problem Actions Taken Results
Test / final
assembly
Metro cart allowed for batching
between prep and test.
Create a FIFO lane, establishing a
max quantity.
FIFO lane is labeled
with the correct max
qty.
Standard WIP defined
between workstations.
FIFO will not hold
more than max qty.
INFOGRAPHICS FINISH GOOD
ASSEMBLYImprovement Ideas
A well defined process to
eliminate batching between
workcells.
Before Kaizen After Kaizen Control Measures
WIP reduction of $6,000
8. INFOGRAPHICS FINISH GOOD
ASSEMBLY
Kaizen Newspaper
Date:9/27/10
Page 1 of 1
No.
Team/Person
Responsible
Due Date
Date
Complete
25 50 75 100
25 50 75 100
25 50 75 100
25 50 75 100
25 50 75 100
25 50 75 100
25 50 75 100
25 50 75 100
27-Sep8
MTO/MTScarts Need 2 more carts made to control kanban size
delivered to line
Commong Herr
1-Oct
7
Terminal blocks are on a metal bar` Need a fixture to retain lables for better point
of use
Commong Herr 27-Sep
6
Tack-ons need to be installed before received at 2HL Tech needs to work with production/associates
need to be trained
Derek Baker
1-Oct
5
Process sheets and BOMs updated Update remaining processes and BOMs to reflect
future state
Derek Baker 1-Oct
4
ICPoint of use/ICfeeder Order ICfeeders and install on 2HL
Jeff Sigmon
27-Sep
2
Changeover carts for test heads Assemble and test fit
Commong Herr
3
Labeling of bins at workcell Label remaining bins including MISC.line
Natasha Lott/Kathy
Harvey/Jean Sylvester
Percent
Complete
1
ACU3 & ACU4 Can assembly Ask vendor to assemble lid and enclosure
before purchase
Natasha Lott 1-Oct
27-Sep
Event Name:Lincolnton Shared event Sept. 13-17th
Kaizen NewspaperTeam Name:Finish Goods assembly and test- Infographics
Observation/Waste I.D. Opportunity Action to be Taken
9. INFOGRAPHICS FINISH GOOD
ASSEMBLY
Lessons Learned
• VSM is the first critical step of a workout
• Create the VSM during the prework
• “Change is not easy”
• Listen and communicate with your team
• Keep scope to a manageable size for the week
• 5S shouldn’t be done only during workouts, it’s a daily task
10. INFOGRAPHICS FINISH GOOD
ASSEMBLY
Lessons Learned
• VSM is the first critical step of a workout
• Create the VSM during the prework
• “Change is not easy”
• Listen and communicate with your team
• Keep scope to a manageable size for the week
• 5S shouldn’t be done only during workouts, it’s a daily task
